High Efficiency Boilers

Why? How?
presented for

Association of Energy Engineers

Feb. 21, 2008

If you ask the wrong question, of course, you get the wrong answer. We find in design its much more important and difficult to ask the right question. Once you do that, the right answer becomes obvious.
Amory Lovins

The Questions
Why care about efficiency? Which efficiency matters? How can boilers get higher efficiency? What is extra cost ? Is it worth it? How to reduce total heating cost?

Why Care About Boiler Efficiency?

Buildings use 39% of energy (gas, electric, other) in the U.S. Certain efficiency levels may be required The major cost of heating is the fuel cost

Total Heating Costs

Over a 5 year period, fuel costs are the major cost of a heating plant operation

Which Efficiency Matters?

Thermal OR Seasonal Peak OR Part Load

Thermal & Seasonal Efficiencies

Thermal Efficiency
One point in time At a given % fire rate At a given Return Water Temperature

Seasonal Efficiency
Weighted average of operating efficiencies Takes into consideration the efficiency at part load conditions

Part Load Is the Focus

Most boiler firing is at 25% to 50% What is boiler efficiency at part load?

How Do Condensing Boilers Function to Get Higher Efficiency?

Condense water vapor from vent gas Continuously vary energy input to match load

Inlet Water Temp Effect on Boiler Efficiency

100 Thermal Efficiency 95 90 85
condensing zone
As the inlet water temp. falls below ~130 F, condensing occurs and boiler efficiency is dramatically increased.

non-condensing zone

80 60 80 100 120 160 180 Inlet Water Temperature

ASHRAE Equipment Handbook, Boiler Chapter

Why a Condensing Design?

Thermal Efficiencies in Excess of 90% System Flexible: Any Water Temperature
Thermal efficiency

Eliminate Thermal Shock Worries Worries Eliminate Primary/Secondary 4-way Pumping and 2, 3 or 4-way Control Valves

100 94 87 80

Condensing Efficiencies

180 130 40 80 Inlet water temperature

Why Modulate the Fuel/Air Input?

Eliminate Cycling Losses No Energy Waste Accurately Match Energy Input to Heating Load No Energy Waste Precise Temperature Control at All Heating Loads Maximize System Efficiency & Simplify Building Controls
100%

Efficiency

Full Modulating Burners

Staged & On/Off Burners Load

100%

0%

ANSI Z21.13 Thermal Efficiency Rating Fact or Fiction?

Hot Water Out System Return Water Fuel Source Thermal Efficiency: (Energy out/Energy in) x 100 but... 180F outlet water

80F inlet water

Is this representative of real heating applications?

ANSI Z21.13-2000: Thermal Efficiency Test BTS -2000: Combustion Efficiency Test
300,000 Btu/h to 12,500,000 Btu/h Test Boiler at Full Capacity

Thermal Efficiency = (Energy Out / Energy In) x 100

Hot Water Supply Flue Gas Temp.

180F, +/- 2

Boiler

Water Flow 80F, +/- 10 Gas Input Return Water

Seasonal Efficiency Depends On

ANSI Z21.13 Ignores All Three

Efficiency Comparison
High Efficiency Mid-Efficiency

Thermal, 100% Fire Thermal, 25% Fire Seasonal Fuel Savings (72:92)

86% 97% ~92% 21.7%

(84%) 77% (84%) 70% ~72%

Installation Results
Cuyahoga County BMR/DD -Maple -Maple Heights, Ohio

28% Reduction in Fuel Usage

How Much Extra Does a Condensing Boiler Cost? Is It Worth It?

Boiler - About 20% Offset - 10% reduction in auxiliary costs Payback - 1 to 3 years NOT a budget breaker

Budget Breaker?
If designer does not change his old design approach, equipment may cost 15-20% more 15-20% - payback is usually one to three heating seasons However: Use of 40F delta T can reduce piping size and pump cost Sidewall or headered venting can save install $$ Sealed combustion can save louver cost Answer - NOT a budget breaker

Is It Worth Doing?

Spreadsheet comparisons Usage factor - estimated Unpublished seasonal efficiency - estimated Handout available

How Can You Reduce Total Heating Cost?

Make good design choices Guide the design team Avoid certain pitfalls Manage the project AFTER installation LEED

Make good design choices

Boiler should modulate, like an accelerator on a car modulate, Reset schedule 140-160F Header temperature should be 140-160F with OAT of 0F Header temperature should be 100F with OAT of 60F Delta T should be 30F to 40F Save pumping and piping costs Added cost in terminal size is modest

Make simplifying design choices

Omit mechanical draft systems Omit pre-heating combustion air pre-heating Omit automatic isolation valves Omit unit circulators

Save Costs -No Unit Circulators

Htg. Load Htg. Load

Reduce/Eliminate Material and Labor: Primary-Secondary Pump, Piping, Elect., Controls, Maintenance AND Improve System Reliability

Guide the Design Team

Forget the old design guidelines Meditate on the pie chart and ASHRAE diagram Make the treasurer happy focus on seasonal efficiency Reflect on the expected life of a boiler - 30 years?

Guide the Design Team

At each design review - ask how seasonal heating efficiency can be higher Boiler cost Does not equal system cost Does not equal total heating system cost over time

Avoid certain pitfalls

Gas pressure Venting Controls coordination Space

Manage the project AFTER installation

System operator training by design engineers Training assistance from equipment suppliers Measure performance - gas usage Compare to a standard Compare to design Schedule maintenance Build cost into the budget

LEED
How to get points with condensing boilers Real-time efficiency monitoring Real-time LEED is required by a number of agencies GSA OSFC More mentioned in January 2008 NEO ASHRAE talk

What do these buildings have in common?

For More Information

C.J. Michelson Co. Manufacturers Agents P.O. Box 16070 Cleveland, OH 44116 440-331-7181 PH 440-331-7181 FAX 440-331-7108 440-331-7108 www.cjmichelson.com